Intermediate wrapper and method of making

ABSTRACT

A tobacco product is formed by perforated cigar or shell, the shell comprising a sheet of material with an intermediate sheet, the sheet comprising tobacco leaves and/or homogenized tobacco paper. The cigar or shell is packaged for shipment to an end user or consumer. The cigar or shell remains in the rolled, shaped tube form inside the package. After the cigar or shell is removed from the package, a consumer can fill the cigar or shell with crushed tobacco leaves or other tobacco filler material of a favorite blend, thereby eliminating some steps in the making of a “roll-your-own” tobacco product. A liquid can be added to the cigar or shell to moisturize same. The liquid can include flavoring.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 12/164,248,filed 30 Jun. 2008, (issuing as U.S. Pat. No. 7,690,386 on 6 Apr. 2010),which was a divisional of U.S. patent application Ser. No. 11/085,822,filed 21 Mar. 2005, which application claimed priority to U.S.Provisional Patent Application Ser. No. 60/584,230, filed 30 Jun. 2004.

Priority of each of the above-referenced applications is hereby claimedand each is incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND

The present invention relates to tobacco products, and more particularlyto a cigar or shell enabling an end user or consumer to prepare a customcigar. The variety, quality and size of ready-made cigars satisfy themajority of the public. However, a small segment of connoisseurs insistthat nothing can compare with the taste and smell of custom-blendedtobacco products. These knowledgeable individuals are very selective inthe manner their cigars are rolled and in the grade of tobacco used. Astill smaller segment of cigar aficionados prefers to roll their owncigars. They buy tobacco leaves or cigar wrappings and use theirpreferred brand of crushed tobacco. Some people buy inexpensive cigars,cut them with a sharp blade along the side, and carefully pry the cutcigar open. The innermost layers are then removed and substituted with afavorite brand of crushed tobacco, which may come from cigarettes orbulk tobacco blend. The user then brings the cut edges of the cigartogether, closing the outer layers of the cigar over the “stuffing.” Theedges are then sealed with a liquid or honey, and a new cigar is readyfor smoking.

Some reports indicate that the roll-your-own tobacco market isflourishing. In some countries, the roll-your-own products now hold asubstantial share of the tobacco market, and their consumers representmore than 10% of the smoking population. This may be explained by theability of a consumer to create a tailor-made product, as opposed tocommercially available types of cigars.

A disadvantage of the existing method of making such custom-made cigarsis that a consumer has to be skillful in the rolling of cigars, that isto have a certain finger dexterity, which would allow him to make thecigar shell without crushing the tobacco leaves. Inexperienced peopleoften become frustrated when the finished product collapses because thecigar was not properly rolled.

One disadvantage of existing roll your own tobacco sheets is arelatively short shelf life based on the loss of moisture.

While certain novel features of this invention shown and described beloware pointed out in the annexed claims, the invention is not intended tobe limited to the details specified, since a person of ordinary skill inthe relevant art will understand that various omissions, modifications,substitutions and changes in the forms and details of the deviceillustrated and in its operation may be made without departing in anyway from the spirit of the present invention. No feature of theinvention is critical or essential unless it is expressly stated asbeing “critical” or “essential.”

BRIEF SUMMARY

The present invention provides an improved cigar or shell forfabricating and making custom made cigars, and a method of making suchcigars or shells that includes preferably tobacco, preferably tobaccoleaves.

The method of the present invention thus enables an end user thatpurchases the packaged cigars or shells to make his or her own cigarswith a selected, custom tobacco filler material. The method preferablyincludes the use of a liquid that includes flavor or flavoring. Theliquid can be, in whole or in part, water, alcohol, solvent, oil,propylene glycol, ethyl alcohol, glycerin, benzyl alcohol as examples.The liquid can be flavored with a flavor such as for example vanilla,honey, berry, chocolate, peach, champagne, cognac, and/or menthol.

With the method of the present invention, the cigar or shell that isformed preferably has a generally cylindrical shape. In a preferredembodiment, a sheet can be single or multiple layered and comprisedentirely of tobacco leaves, or can be a combination of tobacco leavesand other material, which are preferably combustible material(s).

In an alternative embodiment one or more intermediate sheets with one ormore tobacco sheets can be rolled into a cigar tube or shell to resistthe loss of moisture and increase shelf life.

The flavors are preferably added to either the shaped tube (or the sheetof material that includes tobacco) with a liquid. This flavored liquidis typically applied to the tobacco sheet or to the shaped tube atlevels of between about 0.01 to 45% by weight, and preferably betweenabout 0.1% to 10% by weight. This flavored liquid is typically appliedto the sheet of material that includes tobacco (or to the shaped tube)with a carrier liquid such as ethyl alcohol, propylene glycol, water orthe like. Glycerin and invert sugar can also be used as a carrier. Somehumectants can also be used, however, little or no humectants can beused. In general terms, the flavors can be provided by botanicalextracts, essential oils, or artificial flavor chemicals, any one ofwhich or a combination thereof mixed with a carrying solvent such aspropylene glycol, ethyl alcohol, glycerin, benzyl alcohol, or otheralcohol, for example. Other flavors can include cocoa, licorice, coffee,vanilla or other botanical extracts. Essentials oils can be used such aswine essence, cognac oil, rose oil, mate or other oils.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the drawings, wherein like parts aredesignated by like numerals, and wherein:

FIG. 1 is a perspective view of a preferred embodiment showingperforations along a longitudinal line of a cigar.

FIG. 1A is a perspective view of the cigar in FIG. 1 packaged with awrapper.

FIG. 2 is a perspective view of a preferred embodiment showing an etchedor cut line along the longitudinal length of a cigar.

FIG. 3 is a perspective view of a preferred embodiment showing irregularperforations along the longitudinal length.

FIG. 3A is a perspective view of either the cigars of FIG. 1 or 2wherein edges have been opened to allow access to the interior bore ofthe cigar.

FIG. 4 shows a preferred embodiment wherein a tobacco sheet can becombined with a separating sheet.

FIG. 5 shows the tobacco sheet on top of the separating sheet where thetobacco sheet is smaller in all dimensions compared to the separatingsheet.

FIG. 6 shows the tobacco sheet on top of the separating sheet where thetobacco sheet is smaller in two dimensions compared to the separatingsheet.

FIG. 7 is a perspective view showing the tobacco sheet and separatingsheet being rolled.

FIG. 8 is a perspective view showing a shell wherein the tobacco sheetand separating sheet have been rolled together.

FIG. 9 is a perspective view of a rolled shell wherein the separatingsheet serves as the wrapper or packaging.

FIG. 10 is a perspective view of a rolled shell (tobacco sheet andseparating sheet) and a mandrel.

FIG. 10A is a perspective view of the rolled shell of FIG. 10 whereinthe shell is wrapped or packaged.

FIG. 11 is the rolled shell of FIG. 9, but also including a mandrel.

FIG. 12 is a perspective, partial cross-sectional view of a single cigaror shell and a wrapper being boxed with the shell partially pulled fromthe box and the box itself being wrapped.

FIG. 13 is a perspective, partial cross-sectional view of multiplecigars or shells in a single zip-wrapper all of which being boxed andwith the zip-wrapper partially pulled from the box with one cigar orshell partially pulled from the zip wrapper and the box itself beingwrapped.

FIG. 14 is a perspective view of multiple cigars or shells individuallywrapped and placed in a sing carton opening at the top through lid.

FIG. 15 is a perspective view of multiple cigars or shells individuallywrapped and placed in a single carton opening at the side through lid.

FIG. 16 is a top view of an alternative sheet.

FIG. 17 is a top view of a tie which can be used with the sheet of FIG.16.

FIG. 18 is a perspective view of a cigar formed from the sheet of FIG.16.

FIG. 19 is a perspective view of the cigar of FIG. 18 packaged with awrapper.

FIG. 20 is a top view of a an alternative sheet.

FIG. 21 is a perspective view of a cigar formed from the sheet of FIG.20;

FIG. 22 is shows an alternative embodiment having multiple tobaccosheets along with multiple separating sheets.

FIGS. 22A through 22C show the individual tobacco sheets and separatingsheets of FIG. 22.

DETAILED DESCRIPTION OF AT LEAST ONE PREFERRED EMBODIMENT

Detailed descriptions of one or more preferred embodiments are providedherein. It is to be understood, however, that the present invention maybe embodied in various forms. Therefore, specific details disclosedherein are not to be interpreted as limiting, but rather as a basis forthe claims and as a representative basis for teaching one skilled in theart to employ the present invention in any appropriate system, structureor manner.

Reference will now be made to the drawings, wherein like parts aredesignated by like numerals, and wherein. FIG. 1 is a perspective viewof a preferred embodiment showing perforations along a longitudinal line50 of a cigar 10. FIG. 1A is a perspective view of the cigar 10 in FIG.1 packaged with a wrapper 15. A new cigar 10 is shown having a shell 30with longitudinal perforation 50 and tobacco filler material 20contained in bore 35. Cigar 10 can be placed in wrapper 50 to preservefreshness. Cigar 10 can be made in any desired length and with apredetermined diameter.

Cigar 10 can include longitudinal perforation 50 in the longitudinaldirection of arrow 55. In alternative embodiments cigar 10 can includeetched line 60 or irregular longitudinal perforation 70 (FIGS. 2 and 3).FIG. 2 is a perspective view of a preferred embodiment showing anetched, creased, or cut line 60 along the longitudinal length of cigar10. FIG. 3 is a perspective view of a preferred embodiment showingirregular perforations 70 along the longitudinal length. Perforations50, line 60, and irregular perforations 70 allow cigar 10 to be easilyopened by user who wishes to replace tobacco filler material 20 with aselect tobacco filler material 21. Perforations 50, 70 should be smallenough so that air flow will be minimized through the perforations, butlarge enough to allow a user to separate the shell if desired.

Cigar 10 preferably has a serrated perforations 70. The purpose ofserrating perforations 70 is to make the edges 51,52 bond better.Instead of serrations, perforations 70 could be in other shapes orpatterns to enable edges 51,52 to better bond to the outside of cigar 10when rolled.

FIG. 3A is a perspective view of either the cigars 10 of FIG. 1 or 2wherein edges have been opened to allow access to the interior bore ofthe cigar. FIG. 3A shows cigar 10 wherein perforated line 50 has beenopened creating edges 51,52 which can be moved apart in the directionsof arrows 53,54 to allow access to bore 35. Tobacco filler material 20can be removed from bore 35 and replacement tobacco filler material canbe placed in bore 35 while edges 51, 52 are held apart. Edges 51,52 willhave a memory wherein they will tend to roll up in the directions ofarrows 55,56 allowing the user to easily make a new cigar.

FIG. 4 shows a preferred embodiment wherein a tobacco sheet 110 can becombined with a separating sheet 100. FIG. 5 shows the tobacco sheet 110on top of the separating sheet 100 where the tobacco sheet 110 issmaller in all dimensions (arrows 101,102) compared to the separatingsheet 100. FIG. 6 shows the tobacco sheet 110 on top of the separatingsheet 100 where the tobacco sheet is smaller in two dimensions (arrow101) compared to the separating sheet 100. In an alternative embodimenta tobacco sheet 110 (which can be made from homogenized tobacco paper ornatural tobacco leaves) is placed over a sealing/protecting sheet 100(FIGS. 4-6). Sheet 110 is preferably smaller than sheet 100 in thedirection of arrow 101 (FIG. 6) and can also be smaller in the directionof arrow 102 (FIG. 5). Sheet 100 can be plastic, cellophane, polymer,foil, wax paper, or other materials which resist moisture and air flow.

FIG. 7 is a perspective view showing the tobacco sheet 110 andseparating 100 sheet being rolled. FIG. 8 is a perspective view showinga shell 130 wherein the tobacco sheet 110 and separating sheet 100 havebeen rolled together. FIG. 9 is a perspective view of a rolled shell 130wherein the separating sheet serves as the wrapper or packaging. Asshown in FIG. 7 sheet 110 and 100 can be rolled in the direction ofarrow 120 to form a shell 130 as shown in FIG. 8 having bore 113. FIG. 8shows a shell 130 where sheet 100 and sheet 110 are the same dimensionin the direction of arrow 101. FIG. 9 shows a shell 130 where sheet 100is larger than sheet 110 in the direction of arrow 101. In FIG. 9 sheet100 can be used as the packaging for rolled shell 130 by sealing sheet100 on ends 140,150.

FIG. 10 is a perspective view of a rolled shell 130 (tobacco sheet 110and separating sheet 100) and a mandrel/form casing 170. FIG. 10A is aperspective view of the rolled shell 130 of FIG. 10 wherein the shell130 is wrapped or packaged. FIG. 11 is the rolled shell 130 of FIG. 9,but also including a mandrel 170.

Mandrel/form casing 170 can be formed from a rigid or flexible materialin a form of a cylinder of a predetermined length and outer diameter.Mandrel/form casing 170 can be made either hollow, with a centralopening 190, or as a solid body. It is desirable that mandrel/formcasing 170 be substantially inflexible and strong enough to withstandforces applied to mandrel/form casing 170 when shell 130 is rolled.

As shown by FIG. 10 a mandrel 150 (such as a straw) can be used in therolling process shown in FIG. 7. Additionally, shell 130 can be packagedin a separate wrapper 160 leaving mandrel 170 in place. In such a mannermandrel 170 would help keep shell 130 in a cylindrical form duringshipment. FIG. 11 shows sheet 100 being used as the wrapper for shell130 and including mandrel 170.

To use shell 130 the user merely unwraps shell 130 by cutting open ends140,150 (FIGS. 9 and 11) or opening wrapper 160 (FIG. 10A). If mandrel170 was used it is removed. Shell 130 is unwrapped in the direction ofarrow 180 (FIG. 10) and sheet 100 is removed and discarded. Sheet 110can now be filled with the tobacco filler material of the user's choice.Sheet 110 will have a memory which will cause it to tend to roll back upon its own. Thus the user will have an easier time in creating a customcigar and will not need finger dexterity as required with flat sheets.

Sheet 100 is used to substantially increase the shelf life of packagedshell 130. Because shell 130 is made of tobacco when exposed to air itwill tend to dry out and become brittle. Sheet 100 being wrapped aboutsheet 110 provides multiple layers of protection against air flow andconsequent moisture loss.

The finished cigars 10 or shells 130 can be packaged in conventionalcontainers and sold directly to customers who desire to roll their owncigars, but do not have the required finger dexterity. An ultimate userwill remove the cigar 10 or shell 130 from its outer wrapper 15, 160 andprying the cigar 10 or shell 130 open by forcing it open. For the cigarall or part of the tobacco filler material 35 can be discarded. Becausecigar 10 or shell 130 is pre-rolled, it has a “memory” and will attemptto again assume a cylindrical or spiral shape. The user will then fillthe bore 35 with any desired blend of the favorite tobacco and sealedges 51,52 by applying a small amount of moisture to the edges 51,52and bringing the edges 51,52 together. A small amount of pressure may beapplied to the edges 51,52 to cause them to seal them together. For theshell 130 user will then fill the bore 113 with any desired blend of thefavorite tobacco and seal edges 111,112 by applying a small amount ofmoisture to the edges 111,112 and bringing the edges 111, 112 together.In this manner, a custom-tailored cigar is made, answering allrequirements of a connoisseur as to the tobacco blend, size and lengthof a cigar.

In FIGS. 4-11, sheet 110 can be, for example, generally rectangular orsquare in shape. Other shapes for the sheet 110 can be provided such as,for example, triangular, trapezoidal, circular or oval. Sheet 110preferably includes tobacco, and preferably tobacco leaves. Sheet 110preferably comprises a laminated composite of two layers, one innerlayer 114 preferably made of homogenized tobacco material and the otherouter layer 115 preferably made of tobacco leaf material, inner layer114 and outer layer 115 preferably bonded together with cigar glue.Preferably, the outer layer 115 extends beyond the inner layer toprovide for better adhesion of edges 111,112 when rolled. Thehomogenized tobacco material of inner layer 114 can be reconstitutedtobacco sheet material commercially available from Nuway of Connecticut.Outside layer 115 can be tobacco leaf material commercially availablefrom Nuway of Connecticut.

Alternatively, inner layer 114 can be reconstituted tobacco bindermaterial, and outer layer 115 can be reconstituted tobacco wrappermaterial. In the alternative, inner layer 114 can be reconstitutedtobacco binder material, and outer layer 115 can be tobacco leavesbonded thereto. Sheet 110 can be a single layer, in which case it ispreferably made of tobacco leaf material, though it can be made ofhomogenized tobacco material.

As part of the method, the cigar 10 or sheet 110 can be sprayed with aliquid that preferably includes a flavoring.

Cigars 10 or shells 130 can be packaged in any appropriate manner. FIGS.12 through 15 show various examples of packaging. FIG. 12 is aperspective, partial cross-sectional view of a single cigar 10 or shell130 and a wrapper 15,160 being boxed with the shell partially pulledfrom the box and the box itself being wrapped. This figure showspackaging that can be used for any embodiment disclosed in thisapplication. Cigar 10 or shell 130 is shown covered in wrapper 15,160which are both enclosed in box 80. Box 80 can itself be covered bywrapper 90. Flap 95 encases cigar 10 or shell 130 and wrapper 15,160 inbox 80.

FIG. 13 is a perspective, partial cross-sectional view of multiplecigars 10 or shells 130 in a single zip-wrapper 165 all of which beingboxed and with the zip-wrapper 165 partially pulled from the box 161with one cigar 10 or shell 130 partially pulled from the zip wrapper 165and the box 161 itself being wrapped. This figure also shows packagingthat can be used for any embodiment disclosed in this application. Thecigars 10 or shells 130 and zip-wrapper 165 can be enclosed in box 161.Box 161 can itself be covered by wrapper 163 and include window 164 forviewing the cigars 10 or shells 130. Flaps 162 close respective ends ofbox 161.

FIG. 14 is a perspective view of multiple cigars 10 or shells 130individually wrapped and placed in a sing carton 166 opening at the topthrough lid 167. The cigars 10 or shells 130 are individually packagedin wrappers 15,160 and wrappers 15,160 can have indicia 168 whichprovides consumers with information concerning the cigars 10 or shells130, such as flavoring or other information. Carton 166 can itself becovered by wrapper 169.

FIG. 15 is a perspective view of multiple cigars 10 or shells 130individually wrapped and placed in a single carton 200 opening at theside through lid 210. The cigars 10 or shells 130 are individuallypackaged in wrapper 15,160 and wrapper 15,160 can include indicia 220which provides consumers with information such as flavoring or otherinformation. Carton 200 can itself be covered by wrapper 230.

FIG. 16 is a top view of an alternative sheet 240. Sheet 240 can includea plurality of openings 245,246 respectively located on edges 241,242.FIG. 17 is a top view of a tie 250 which can be used with sheet 240.FIG. 18 is a perspective view of a cigar 10 formed from sheet 240 andtie 250. Bore 35 of cigar 10 can be filled with tobacco filler material20. Tie 250 can be threaded through openings 245,246 to hold cigar 10 ina cylindrical shape. Alternatively openings 245,245 can be formed aftersheet 240 has been rolled into a cylindrical shape and filled withtobacco filler material 20. Openings 245,246 can be formed at the sametime tie 250 is inserted into the openings, such as by stitching with asewing machine. Tie is shown relatively loose but can be as tight asdesired causing edges 241,242 to touch. FIG. 19 is a perspective view ofthe cigar 10 of FIG. 18 packaged with a wrapper 15.

When a user desires to insert his tobacco fill material of choice, tie250 can be cut or untied from openings 245,246 and edges 241,242 can bepulled apart providing access to bore 35. Tobacco filler material 20 canbe removed from bore 35 and replacement tobacco filler material can beplaced in bore 35 while edges 241,242 are held apart. Edges 241,242 willhave a memory wherein they will tend to roll up in the directions ofarrows 247,248 allowing the user to easily make a new cigar.

FIG. 20 is a top view of a an alternative sheet 260 showing an area 270which can be easily separate when desired. FIG. 21 is a perspective viewof a cigar 10 formed from sheet 260 where edges 261,261 have beenattached and bore 35 has been filled with tobacco filler material 20.Area 270 can be formed by causing it to be of less thickness than theremaining portion of sheet 260. For example, were sheet 260 to be formedfrom a layer of binder and a layer of wrapper, area 270 may be formed byremoving the binder or removing the wrapper thereby making it weakerthan the remaining part of sheet 260. Various other processes can beapplied to area 270 to make it weaker than the remainder of sheet260—such as scarring, scratching, etching etc. Where stress is appliedto area 270 sheet 360 will separate along area 270 and into edges 271,272. During the manufacturing process of cigar 10 edges 261,262 wereoverlapped and sealed and are not easily separable. Selected tobaccofiller material can then be placed in bore 35 and a custom cigar made bythe user.

FIGS. 22A through 22C show an alternative embodiment having multipletobacco sheets 110A,110B,110C along with multiple separating sheets100A,100B,100C, placed together and forming multiple sheet rolled shell132. As shown in FIG. 22, multiple tobacco sheets 110A,110B,110C can becombined with multiple separating sheets 100A,100B,100C to form shell132 having bore 133. The tobacco sheets 110 and separating sheets 100can be stacked in an alternating manner and rolled into a rolled shell132. Shell 132 can then be encased in a wrapper/packaging 15.Alternatively, additional tobacco sheets 110 (e.g., four or more) can beused forming multiple sheet rolled shell 132. Also alternatively, merelytwo tobacco sheets 110A,110B can be used forming multiple sheet rolledshell 132. Also alternatively, a smaller number of separating sheets 100can be used than the number of tobacco sheets 110. For example, in oneembodiment only an outer separating sheet 110C is used with multipletobacco sheets 110A,110B,110C. As another example, only an innerseparating sheet 100A is used with multiple tobacco sheets110A,110B,110C. As another example, alternating separating sheets100A,100C are used with multiple tobacco sheets 110A,110B,110C. Alsoalternatively, more separating sheets 100 can be used than tobaccosheets 110. Additionally, more or less than three tobacco sheets 110 canbe used. Alternatively, similar to the embodiments shown in FIGS. 9 and11, separating sheets 100A,100B, and/or 100C can be used as thewrapper/packaging (either all separating sheets 100 or a portion of allseparating sheets 100). Additionally, with any of these embodimentsrolled, shell 132 (e.g., tobacco sheets 110A,110B,110C and separatingsheets 100A,100B,100C) can include a mandrel/form casing 170.Mandrel/form casing 170 can assist rolled shell 132 in maintaining itsshape after being packaged.

In another alternative embodiment, tobacco sheet 110A and separatingsheet 100A are first rolled into rolled shell 130 and then tobacco sheet110B and separating sheet 100B are then rolled over shell 130 to formrolled shell 132. Alternatively, multiple rolled shells can be formed inthis manner with alternating tobacco sheets 110 and separating sheets100. The order of tobacco sheets 110 and separating sheets can bevaried, such as having inner tobacco sheets 110 and outer separatingsheets 100; or inner separating sheets 100 and outer tobacco sheets 110.Alternatively, one or more separating sheets 100 can be omitting fromrolled shell 132.

Those skilled in the art will understand that various materials forwrapping can be used to enclosed the tubes or shells. These include, butare not limited to, Low & High Density Polyethylene with EVA additive,Linear Low Density Poly, Polypropylene, Orientated Polypropylene, CastPolypropylene, PVC, Polyester, Vaper Barrier packaging, Moisture Barrierpackaging, Laminated packaging, Shrink film, Stretch Film, Foil Films(which can be translucent or opaque), Metalized Film, Cellophane, andPolyethylene Terephthalat. In addition to an “EVA” additive a barrierfoil lamination can be used being either coated or metallized. Thepackaging of the present invention, whether plastic, aluminum, or glass,keeps moisture in or dramatically slows down moisture loss from thetubes or shells. It is preferable that the wrapping material haveadequate moisture resistant properties so that the tubes or shells donot dry out before use by consumers.

REFERENCE NUMERAL LIST

REFERENCE NO. DESCRIPTION 10 cigar 15 wrapper/packaging 20 tobaccofiller material 21 tobacco filler material 30 shell 35 bore 50perforations 51 edge 52 edge 53 arrow 54 arrow 55 arrow 56 arrow 60 line70 perforations 80 box 90 wrapper 95 flap 100 separating sheet 101 arrow110 tobacco sheet 111 edge 112 edge 113 bore 114 inner layer 115 outerlayer 120 arrow 130 shell 132 shell 134 arrow 140 end 150 end 160wrapper 161 box 162 flap 163 wrapper 164 window 165 wrapper 166 carton167 lid 168 indicia 169 wrapper 170 mandrel 180 arrow 190 opening 200carton 210 lid 220 indicia 230 wrapper 240 sheet 241 edge 242 edge 245openings 246 openings 247 arrow 248 arrow 250 cord/string/thread/tie 260sheet 261 edge 262 edge 270 area 271 edge 272 edge

It will be understood that each of the elements described above, or twoor more together may also find a useful application in other types ofmethods differing from the type described above. Without furtheranalysis, the foregoing will so fully reveal the gist of the presentinvention that others can, by applying current knowledge, readily adaptit for various applications without omitting features that, from thestandpoint of prior art, fairly constitute essential characteristics ofthe generic or specific aspects of this invention set forth in theappended claims. The foregoing embodiments are presented by way ofexample only; the scope of the present invention is to be limited onlyby the following claims.

1. A method of making a custom made cigar comprising the steps of: (a) aconsumer purchasing a cigar packaged for sale, the cigar having a shell,the shell having first and second ends and a longitudinal bore, the borebeing filled with tobacco filler, the shell having a plurality ofperforations which can be opened providing access to the tobacco filterand causing the cigar to have first and second longitudinal edgeportions; (b) the consumer removing the cigar from the packaging andopening the cigar along the perforations forming first and second edgeportions, and moving apart the first and second edge portions to provideaccess to the tobacco filler in the bore; (c) the consumer removing atleast part of the tobacco filler from the bore; and (d) the consumeradding new tobacco to the bore, sealing the shell, thereby forming acustom-tailored cigar.
 2. The method of claim 1, wherein in step “c” allof the tobacco filler is removed from the bore.
 3. The method of claim1, wherein in step “a” the shell is comprised of homogenized tobaccopaper.
 4. The method of claim 1, wherein in step “a” the shell iscomprised of natural tobacco leaves.
 5. The method of claim 1, whereinin step “a” the plurality of perforations are in a straight line acrossthe longitudinal length of the bore.
 6. The method of claim 1, whereinin step “a” the plurality of perforations form an irregular shape. 7.The method of claim 1, wherein in step “a” the plurality of perforationsform an zig zag shape.
 8. The method of claim 1, wherein in step “a” theplurality of perforations allow the cigar to be easily opened.
 9. Themethod of claim 1, wherein in step “a” the plurality of perforations aresmall enough so that air flow through the perforations is minimized, buylarge enough to allow a consumer to separate the perforations.
 10. Themethod of claim 1, wherein in step “a” the cigar is packaged for sale asa single cigar in a wrapper.
 11. The method of claim 1, wherein in step“a” the cigar is packaged for sale in a multiple cigar zip-wrapperpackaging.